Power Tool System Having In-Station Verification Utilizing Radio Frequency Signal Strength

• US 20170199509A1
• Filed: 01/08/2016
• Published: 07/13/2017
• Est. Priority Date: 01/08/2016
• Status: Active Grant

• Current Assignee: Newfrey Llc (Stanley Black & Decker, Inc.)
• Original Assignee: Newfrey Llc (Stanley Black & Decker, Inc.)
• Inventors: KHALAF, Zuher Naim
• Granted Patent: US 10,078,322 B2
• Time in Patent Office: Days
• CPC Class Codes: B25B 23/147 specially adapted for electrically operated wrenches or screwdrivers
• CPC Class Codes: G05B 19/402 characterised by control arrangements for positioning, e.g. centring a tool relative to a hole in the workpiece, additional detection means to correct position G05B19/19 takes precedence
• CPC Class Codes: G05B 19/41805 characterised by assembly
• CPC Class Codes: G05B 2219/35519 Machining data and tool data
• CPC Class Codes: G05B 2219/45127 Portable, hand drill
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

The industrial power tool system includes a controller physically disposed in a predefined location within an assembly line work station. The controller has a first radio frequency transceiver that propagates a digital communication signal at a predefined power. A human operable portable power tool has a second radio frequency transceiver configured to communicate with the first transceiver, providing a signal strength datum indicative of the received signal strength. A processor circuit causes the tool to perform a sequence of predefined assembly job steps that are mediated by the processor circuit according to a control loop running on the processor circuit. The processor circuit compares the signal strength datum to a predefined signal strength threshold to determine if the distance between the first and second radio frequency transceivers is less than a predefined distance that defines a home area proximate the controller. The processor circuit uses the test of this distance as at least one operative step in the control loop that mediates the sequence of predefined assembly job steps.

Claims

1. An industrial power tool system for use on a production line having plural work stations, comprising

a controller physically disposed in a predefined location within a first one of said work stations, the controller having a first radio frequency transceiver configured to propagate a digital communication signal at a predefined power;

a human operable portable power tool having a second radio frequency transceiver configured to communicate with the first radio frequency transceiver and providing a signal strength datum indicative of the received signal strength of the propagated digital communication signal of the first radio frequency transceiver;

the portable power tool having a processor circuit that is programmed to cause the tool to perform a sequence of predefined assembly job steps that are mediated by the processor circuit according to a control loop running on the processor circuit;

wherein the processor circuit is programmed to interrogate the signal strength datum and to compare the signal strength datum to a predefined signal strength threshold to thereby determine if the distance between the first and second radio frequency transceivers is less than a predefined distance that defines a home area proximate the controller;

wherein the processor circuit is programmed to test whether the tool is within the home area using said signal strength comparison and to use said test as at least one operative step in the control loop that mediates the sequence of predefined assembly job steps.

2. The system of claim 1 wherein the first and second radio frequency transceivers operate according to a layered communication standard that includes a data link layer that mediates the transfer of data between the first and second radio frequency transceivers and that further includes a physical layer that regulates the physical connectivity between the first and second radio frequency transceivers, and which physical layer mediates the generation of said signal strength datum.

3. The system of claim 1 wherein the first and second radio frequency transceivers operate according to a WiFi protocol and wherein at least the second radio frequency transceiver measures signal strength of signals received at its antenna input and supplies said measured signal strength as the signal strength datum.

4. The system of claim 1 wherein the portable power tool has a case and wherein the second radio frequency transceiver and the processor circuit of the portable power tool are disposed within the case.

5. The system of claim 1 wherein the portable power tool includes a battery and wherein the second radio frequency transceiver and the processor circuit are energized by said battery.

6. The system of claim 1 further comprising at least one limit switch or sensor disposed on the production line and positioned to detect when a workpiece is positioned at said one of said work stations, the at least one limit switch or sensor generating a control signal that is supplied to the controller and that defines at least one operative step in the control loop that mediates the sequence of predefined assembly job steps.

7. The system of claim 6 wherein the control signal is communicated by the controller to the tool by wireless communication using said first and second radio frequency transceivers.

8. The system of claim 1 further comprising a second portable power tool having a second processor circuit that is programmed to cause the second tool to perform a second sequence of predefined assembly job steps that are mediated by the second processor circuit according to a second control loop running on the second processor circuit and associated with a second one of said work stations,

wherein the second control loop running on said second power tool uses a signal strength datum in said second control loop to prevent the second power tool from operating with the first one of said work stations.

9. The system of claim 1 further comprising a second portable power tool electronically implementing a second control loop that relies on a signal strength datum to prevent the second power tool from operating at said first one of said work stations.

10. A method of operating an industrial power tool system for use on a production line having plural work stations, comprising

deploying a controller at a predefined physical location within one of said work stations, the controller having a first radio frequency transceiver configured to propagate a digital communication signal at a predefined power;

providing a human operable portable power tool having a second radio frequency transceiver configured to communicate with the first radio frequency transceiver and providing a signal strength datum indicative of the received signal strength of the propagated digital communication signal of the first radio frequency transceiver;

using a programmed processor circuit with the portable power tool to cause the tool to perform a sequence of predefined assembly job steps that are mediated by the processor circuit according to a control loop running on the processor circuit;

using the programmed processor circuit to interrogate the signal strength datum and to compare the signal strength datum to a predefined signal strength threshold to thereby determine if the distance between the first and second radio frequency transceivers is less than a predefined distance that defines a home area proximate the controller; and

using the programmed processor circuit to test whether the tool is within the home area using said signal strength comparison and to use said test as at least one operative step in the control loop that mediates the sequence of predefined assembly job steps.

11. The method of claim 10 wherein the first and second radio frequency transceivers operate according to a layered communication standard that includes a data link layer for mediating the transfer of data between the first and second radio frequency transceivers and that further includes a physical layer for regulating the physical connectivity between the first and second radio frequency transceivers, and

further comprising mediating the generation of said signal strength datum using said physical layer.

12. The method of claim 10 wherein the first and second radio frequency transceivers operate according to a WiFi protocol and wherein at least the second radio frequency transceiver measures signal strength of signals received at its antenna input and supplies said measured signal strength as the signal strength datum.

13. The method of claim 10 further comprising energizing the second radio frequency transceiver and the processor circuit using a battery attached to the portable power tool.

14. The method of claim 10 further comprising generating a control signal by detecting when a workpiece is positioned at said one of said work stations using at least one limit switch or sensor disposed on the production line;

and

using said control signal to define at least one operative step in the control loop that mediates the sequence of predefined assembly job steps.

15. The method of claim 14 wherein the control signal is communicated by the controller to the tool by wireless communication using said first and second radio frequency transceivers.

16. The method of claim 10 further comprising providing a second portable power tool having a second processor circuit that is programmed to cause the second tool to perform a second sequence of predefined assembly job steps that are mediated by the second processor circuit according to a second control loop running on the second processor circuit and associated with a second one of said work stations;

and

using a signal strength datum in the second control loop to prevent the second power tool from operating with the first one of said work stations.

17. The method of claim 10 further comprising providing a second portable power tool electronically implementing a second control loop;

and

using a signal strength datum to prevent the second power tool from operating at said first one of said work stations.

18. A non-transitory computer readable medium that stores a program which when operated upon by a processor circuit causes the processor circuit to perform the following:

causing a portable power tool associated with said processor circuit to perform a sequence of predefined assembly job steps that are mediated by the processor circuit according to a control loop running on the processor circuit;

processing a radio frequency signal from a signal source to obtain a signal strength datum reflecting the strength of the radio frequency signal and comparing the signal strength datum to a predefined signal strength threshold; and

using the signal strength comparison as at least one operative step in the control loop that mediates the sequence of predefined assembly job steps.